Method for applying mastic paint compositions to concrete bases

ABSTRACT

A mastic paint composition for concrete is prepared by adding to a mixture of Portland cement with aggregates the following: calcium chloride, naphthalene sulfonic acid formalin condensate, alkyl cellulose, propylene glycol and known additives, such as calcium sulfoaluminate as an antishrinking agent, zeolite as an efflorescence preventing agent, calcium stearate as a waterproofing agent and tributyl phosphate as a defoaming agent as well as coloring agents. A rubber latex or an emulsion of a vinyl resin may also be added. This paint comprosition is made by kneading these components with addition of water into a paste. In applying this paste to a concrete base, there is no need of treating the surface of the base beforehand, but the paste can be applied with a porous hand-roller directly to the untreated concrete base, and a mastic finish can be obtained in one shot.

WUnited States Patent [191 Suzuki et a1.

[ METHOD FOR APPLYING MASTIC PAINT COMPOSITIONS TO CONCRETE BASES [75]Inventors: Yoshinori Suzuki; Yukio Iwasaki,

both of Tokyo, Japan [73] Assignee: Kowa Chemical Industry Ltd., Tokyo,Japan [22] Filed: June 9, 1972 [21] Appl. No.: 261,297

[58] Field 01 Search 106/90, 93, 95; 117/111 R,

117/111 D, 125 A, 169 A, 111 A; 52/515 [56] References Cited UNITEDSTATES PATENTS 2,892,728 6/1959 Jolly 106/90 2.959.489 ll/l960 Wagner106/90 3,030,258 4/1962 Wagner 106/93 3,051,590 8/1962 Proux 117/123 A3,169,877 2/1965 Bartoli 106/93 3,487,038 12/1969 Toy et a1 106/903,538,036 ll/1970 Peters et a1. 106/90 3,663,287 5/1972 Mizunnma 106/93FOREIGN PATENTS OR APPLICATIONS 628,553 6/1963 Belgium 106/90 [451 Dec.17, 1974 OTHER PUBLICATIONS Chemical Abstracts, Vol, 70: 80587e, 1969.Chemical Abstracts, Vol. 58: 9946a, 1963.

Primary Examiner-William D. Martin Assistant Examiner-William H. SchmidtAttorney, Agent, or Firm-McGlew and Tuttle [5 7] ABSTRACT Ama'stic,paint composition for concrete is prepared by adding to amixture of Portland cement with aggregates the following: calciumchloride, mu}llthalenesttb- Tata ci' mmulsion of a vi in ay also bemmmfifiigg fi kneading these components with addition of water into apaste. In applying this paste to a concrete base, there is no need oftreating the surface of the base beforehand, but the paste can beapplied with a porous hand-roller directly to the untreated concretebase, and a mastic finish can be obtained in one shot.

10 Claims, No Drawings SUMMARY OF THE INVENTION The present inventionrelates to a paint composition and a method of applying this paintcomposition to a concrete base. More particularly, the invention relatesto a paint composition which can be applied directly to an untreatedbase, and a method for applying the paint composition to the base.

BACKGROUND OF THE INVENTION AND PRIOR ART Among the methods for applyingpaint to a concrete base, brush-coating and spray-gun coating methodsare well-known. Before paint is applied to a concrete base with a brush,usually the surface of the base is polished by a grinder in order toremove the unevenness or irregularities on the bases surface, and thenthe base is coated with mortar or putty, and furthr smoothed away bysand paper, and treated with a sealer primer. Then under coating, secondcoating and finishing coating are applied to the pretreated surface ofthe base by brush. In case a spray gun is used, the surface of the baseis tidied up and the unevenness and irregularities are removed; pinholes are plugged up, and a sealer primer is applied to the surface ofthe base before under spraying and finishing spraying of the paint arecarried out with the spray gun.

However, the known methods of coating concrete involve a number ofcomplicated processes, and much time and labor are required for theirpractice. Especially when hydraulic cement is sprayed by a spray gun ata low temperature, as is usually the case in giving a scratching finishof stucco, efflorescence is apt to take place, for which there is noremedy. What is worse, a

considerable skill is required for spraying paint with a spray gun,accompanied by not a little material loss. If hanging-type scaffolds areconstructed for the paintspraying ofa building. instead of expensiveproper scaffolding. operational difficulty is increased, and the painttends to be applied unevenly.

Many studies have been made for the purpose of overcoming thedisadvantages involved in the known methods, but no satisfactorysolution has been obtained as yet.

OBJECTS OF THE INVENTION An object of the invention is to provide novelpaint compositions which can be applied directly to concrete baseswithout subjecting the bases to any pretreatment. Another object is toprovide a method for applying said compositions to these bases.

Still another object of the invention is to provide a method forcarrying out the application of thepaint compositions in one shot togive thick films thereof, which films then need to be coated only with aprotective material as the finish coat.

-Yet another object of the invention is to provide paint compositionswhich are of the room temperature drying type, which have a short curingtime, and which can not crack or fall off after applied.

One more object of the present invention is to give coated surfaces forindoor or outdoor use, which exhibit superior resistance to fading andweathering. which present a glossy, ceramic appearance like that oftiles, and which give no pain to human bodies coming into contact withthem. Moreover, it is an object to provide such coated surfaces whichare washable with water while their color hardly changes or fades withthe lapse of time.

DESCRIPTION OF THE INVENTION The paint composition employed inpracticing the method of the invention is prepared by adding to amixture of Portland cement and an aggregate, the following: l -3 partsof calcium chloride, 0.4 -2 parts of naphthalene sulfonic acid formalincondensate, l -2 parts of alkyl cellulose, and 2 -5 parts of propyleneglycol, all of said parts being per I00 parts of the Portland cement.Further, the following are added to the mixture: an antishrinking agent,an efflorescence preventive agent, a waterproofing agent, a defoamingagent, a coloring agent, and water, then the resulting mixture isprocessed into a paste. The paste is applied by means of a porous handroller to the surfaces of a concrete base, thereby carrying out a masticcoating, along with the treatment of the base, in a one coat finish.

Calcium chloride added to the composition serves as a cure modifier, itsamount being l-3 parts per I00 parts of the cement. The amounts ofnaphthalene sulfonic acid formalin condensate, alkyl cellulose, andpropylene glycol are suitably in the ranges of'0.4-2 parts, 1-2 parts,and 2-5 parts, respectively, and if they are more or less than what aregiven above, desired results can hardly be obtained. As the alkylcellulose, either methyl cellulose or ethylceliglose is used, having ahigh gel point, preferably above C. As the naphthalene sulfonic acidformalin condensate, the sodium salt of a-methyl naphthalene sulfonicacid formalin condensate is used. To the mixture 0.5-l0 parts of calciumsulfoaluminate may be added as an antishrinking agent, 5-15 parts ofzeolite as an efflorescence preventive agent, 0.1-5 parts of calciumstearate may be added as a waterproofing agent, and U.Ol-0.2 part oftributyl phosphate may be added as a defoaming agent, as well as acoloring agent in such an amount as to meet the purpose for which it isemployed.

Ifa syggietic rubber latex such as styrene-butadiene rubber or a m resinemulsion such as acrylic ester copolymer is added to the above-givenmixture, 11 film of more uniform quality will be produced, and the bondbetween the finishing coat and the film formed of the paint compositionof the present invention will be strengthened. Further, if vinyl paintor acrylic acid paint is applied to the above-given composition-coatedbase to give a protective layer ofa synthetic resin, a still morebeautiful decorative layer will be formed.

The method of the present invention is quite different from an ordinaryroller painting method which comprises applying a paint composition,containing finely divided white lime stone with a brush roller only tothe surfaces of a porous base.

The method of the invention is also different from a roller applicationof a sandtextured coating, in which the aggregates mixed in thecomposition are apt to get together or fly about, causing a big loss,which is liable to end in uneven finish.

In order to achieve a satisfctory mastic coating, it is usually requiredto have the paint composition applied several times, so that the coatinglayers become thick and tend to crack during drying.

adhesion and water resistance as well as beautiful appearance of thepatterns as a finish.

The method of the present invention is best used in the coatingofinorganic materials for indoor or outdoor use. The films formed. afterbeing allowed to stand for 28 days, have surfaces exhibiting glassyunevenness like that of ceramic tiles and such films serve the purposeof decorative coating, which covers any irregularities and pinholes onthe surfaces of the base.

The maximum thickness of the film prepared with the paint composition ofthe invention is from 2 to 3 mm, and its properties are given in Table 2which follows.

3. lmpact resistance (on 28 day- X 75 presented y the film anduniformity of its color. No change at 1 kg .llS-A-5403 4. Adhesion Morethan 3 kg/cm An adhesion tester (Under normal kept at theArchitectcondition) ural Research Institute of the Ministry ofConstructton was employed in conducting the test.

5. Abrasion test 95 mg/LOOO Taber's abrasion test- (on 28 daytimes er.(Abraser: H 22. old film} load: 250 g) 6. Washability No change afterJlS-A 6909 being washed 2.000 times. 7. Degree of lust- More than 70.llS-K 5400 cr 8. Freeze thaw No change after ln accordance withstability c cles. ASTM C-290-6IT 9. Water penctuantity of water JlS-A6l0l ration (on 28 penetrated: None Water pressure: 0.1 day-old film)kg/cm. l0. Accelerated No change after Irradiation by a weathenng 1.000hours weathermeter Table l Number of Amount (21f Amount 0% fl\j/orkMethod coats paint use paint coate e lcienc (kg/m (kg/m) (m"/mand y)Method of present invention 1 l.3l.8 l.2-l.7 60-70 Scratching of ahydraulic cement 2 l.2-l .3 0.8-].0 60

Sprayin of a sandtexture paint 2 0.7l.7 0.5-1.2 compositlon The surfacesof the scratching-finished concrete base DESCRIPTION OF SPECIFICEMBODIMENTS usually become dirtier with the passage of time, whereas thesurfaces of the concrete base treated by the method of the invention,according to experience, were only a little contaminated even after thelapse of 2 years and 6 months; the contamination could be removed bywashing with water.

Generally. coating conditions differ somewhat depending on whether thecoat is applied, for example, to walls or to ceilings of a room. eitherindoors or outdoors.

What is particularly required of outdoor coating is weather resistance,water resistance. adhesion. cleanliness and rigidity; while as to indoorcoating. what is required of the wall coating is adhesion, waterresistance and rigidity. and what is required of ceiling coating is Theinvention will be further illustrated by the following examples.

EXAMPLE 1.

Table 3 Ingredients of the paint commisition of Example I EXAMPLE 2.

To 100 parts of the powdery paint composition consisting of theingredients stated below in Table 4 were added 70 parts of water and 20parts of 46 percent acrylic ester copolymer emulsion. The mixture waskneaded into a paste. The paste was applied at a rate of2.0 kg/m to l0lin outdoor concrete wall ofa metal form which had not been pretreated.After the lapse of 24 hours, (temperature: 20C, relative humidity: 65percent), white enamel (solid content: percent) in a toluol solution ofan acrylic ester copolymer was applied to the film prepared of the paintcomposition at the rate of 0.4 kg/m*. As a result. glassy unevennesslike the one given by ceramic tiles, was given covering the pinholes onthe surface of the concrete base. No crack or peeling off of the coatingpaint was observed. The work efficiency was 70 m lman-day. The film ofthe soprepared paint composition was observed to possess propertiessimilar to those shown in Example I. The addition of the polymeremulsion to the paint composition proved to help produce a film ofuniform quality and improve the adhesion of the film to the finishingmaterial.

Table 4 ln edients of the aim com sition of Exam le 2 Item Kin% Bywetght Cement Hydraulic white Portland cement I00 Silica sand (l 00-2O0mesh) A egate I Jggr Anatzmc titanium dioxide Pigment Zool ite Calctumchloride I I I Naphthalene sulfontc acid formalin condensate C alctumstearatc I Calcium sulfoalumtnate Mcthylccllulosc (4000 cp) Tnbutphosphate Propy cnc glycol Additives What is claimed is:

1. Method for applying a mastic coating to a concrete base whichcomprises applying to said concrete base, with a porous hand roller in aone coat finish, a pasty paint composition comprising a mixture of (a)Portland cement, (b) an aggregate, (c) from about I to about 3 parts byweight of calcium chloride, (d) from about 0.4 to about 2 parts byweight of naphthalene sulfonic acid formalin condensate, (e) from about1 to about 2 parts by weight of alkyl cellulose having a viscosity ofabout 4.000 cps, (f) from about 2 to about 5 parts by weight ofpropylene glycol, (g) from about 0.5 to about 10 parts by weight ofcalcium sulfoaluminate, (h) from about 5 to about 15 parts by weight ofan efflorescence preventing agent consisting essentially of zeolite, (i)front about 0.l to about 5 parts by weight of calcium stearate, and (j)from about 0.01 to about 0.2 part by weight of tributyl phosphate, allof said parts being based upon parts of said Portland cement, and saidaggregate being present in an amount of from about l00 to about parts byweight.

2. The method claimed in claim 1 in which a synthetic rubber latex isadded to the pasty paint compositton.

3. The method of claim 2, in which styrene-butadiene rubber latex isadded to the pasty paint composition.

4. The method claimed in claim 1 in which a vinyl resin emulsion isadded to the pasty paint composition.

5. The method of claim 4, in which acrylic ester c0- polymer is added inthe form of an emulsion to the pasty paint composition.

6. The method of claim 1, wherein the aggregate is silica sand.

7. The method of claim 6, wherein the alkylcellulose is methylcellulose.

8. Method for applying a mastic coating to a concrete base whichcomprises applying to said base, with a porous hand roller in a one-coatfinish, a pasty paint composition comprising a mixture of (at) Portlandcement, (b) an aggregate, (c) from about I to about 3 parts by weight ofcalcium chloride, (d) from about 0.4 to about 2 parts by weight ofnaphthalene sulfonic acid formalin condensate, (e) from about I to about2 parts by weight of alkylcellulose having a viscosity of about 4,000cps, and (f) from about 2 to about 5 parts by weight of propyleneglycol, all of said parts being based upon I00 parts of said Portlandcement, and said aggregate being present in an amount of from about lOOto about 150 parts by weight.

9. The method of claim 8, which includes adding a synthetic rubber latexin the pasty paint composition.

10. The method of claim 8, which includes adding a vinyl resin emulsionin the pasty paint composition.

1. A METHOD FOR APPLYING A MASTIC COATING TO A CONCRETE BASE WHICHCOMPRISES APPLYING TO SAID CONCRETE BASE, WITH POROUS HAND ROLLER IN AONE COAT FINISH, A PASTY PAINT COMPOSITION COMPRISING A MIXTURE OF (A)PORTLAND CEMENT, (B) AN AGGRE: GATE (C) FROM ABOUT 1 TO ABOUT 3 PARTS BYWEIGHT OF CALCIUM CHLORIDE, (D) FROM ABOUT 0.4 TO ABOUT 2 PARTS BYWEIGHT OF NAPHTHALENE SULFONIC ACID FORMALIN CONDENSATE, (E) FROM ABOUT1 TO ABOUT 2 PARTS BY WEIGHT OF ALKYL CELLULOSE HAVING A VISCOSITY OFABOUT 4,000 CPS, (F) FROM ABOUT 2 TO BOUT 5 PARTS BY EIGHT OF PROPYLENEGLYCOL, (G) FROM ABOUT 0.5 TO ABOUT 10 PARTS BY WEIGHT OF CALCIUMSULFOALUMINATE, (I) FROM ABOUT 0.1 TO TO ABOUT 15 PARTS BY WEIGHT OF ANEFFLORESCENCE PREVENTING AGENT CONSISTING ESSENTIALLY OF ZEOLITE, (I)FROM ABOUT 0.1 TO ABOUT 5 PARTS BY WEIGHT OF CALCIUM STEARATE, AND (j)FROM ABOUT 0.1 TO ABOUT 0.2 PARTS BY WEIGHT OF TRIBUTYL PHOSPHATE, ALLOF SAID PARTS BEING BASED UPON 100 PAARTS OF SAID PORTLAND CEMENT, ANDSAID AGGREGATE BEING PRESENT IN AN AMOUNT OF FROM ABOUT 100 TO ABOUT 150PARTS BY WEIGHT.
 2. The method claimed in claim 1 in which a syntheticrubber latex is added to the pasty paint composition.
 3. The method ofclaim 2, in which styrene-butadiene rubber latex is added to the pastypaint composition.
 4. The method claimed in claim 1 in which a vinylresin emulsion is added to the pasty paint composition.
 5. The method ofclaim 4, in which acrylic ester copolymer is added in the form of anemulsion to the pasty paint composition.
 6. The method of claim 1,wherein the aggregate is silica sand.
 7. The method of claim 6, whereinthe alkylcellulose is methyl cellulose.
 8. Method for applying a masticcoating to a concrete base which comprises applying to said base, with aporous hand roller in a one-coat finish, a pasty paint compositioncomprising a mixture of (a) Portland cement, (b) an aggregate, (c) fromabout 1 to about 3 parts by weight of calcium chloride, (d) from about0.4 to about 2 parts by weight of naphthalene sulfonic acid formalincondensate, (e) from about 1 to about 2 parts by weight ofalkylcellulose having a viscosity of about 4,000 cps, and (f) from about2 to about 5 parts by weight of propylene glycol, all of said partsbeing based upon 100 parts of said Portland cement, and said aggregatebeing present in an amount of from about 100 to about 150 parts byweight.
 9. The method of claim 8, which includes adding a syntheticrubber latex in the pasty paint composition.
 10. The method of claim 8,which includes adding a vinyl resin emulsion in the pasty paintcomposition.